Electric machine including a switch terminal and method of connecting an end portion of a wire to a terminal of an electric machine

Abstract

An electric machine includes a wire conductor having at least one end, a terminal configured to be operatively connected to the at least one end of the wire conductor, and a terminal member having a first end section configured and disposed to establish a mechanical bond and an electrical connection with the at least one end of the wire conductor, and a second end section configured and disposed to establish a mechanical link and an electrical connection with the terminal.

1. An electric machine comprising:
 a wire conductor including at least one end; 
 a terminal configured to be operatively connected to the at least one end of the wire; and 
 a terminal member having a first end section, a second end section and an opening positioned between the first and second end sections, the at least one end of the wire extending into the opening and being joined to the terminal member through a mechanical bond and electrical connection, the second end section being configured and disposed to establish a mechanical link and an electrical connection with the terminal. 
 
     
     
       2. The electric machine according to  claim 1 , wherein the terminal includes a connecting surface having an opening, the second end section of the terminal member being configured and disposed to extend through the opening and engage the connecting surface to establish the mechanical link. 
     
     
       3. The electric machine according to  claim 2 , wherein the second end section of the terminal member includes a first connecting member and a second connecting member, each of the first and second connecting members being configured and disposed to be independently deformed to engage the connecting surface to establish the mechanical link. 
     
     
       4. The electric machine according to  claim 2 , further comprising: an amount of solder arranged at the second end section of the terminal member, the amount of being configured and disposed to facilitate the electrical connection with the terminal. 
     
     
       5. The electric machine according to  claim 1 , further comprising: a diode having a first diode terminal and a second diode terminal, the opening includes a first opening portion having a size that is greater than a size of an outer perimeter of at least one of the first and second diode terminals and a second opening portion having a size that is less than the size of the outer perimeter of the one of the first and second diode terminals. 
     
     
       6. The electric machine according to  claim 1 , wherein a portion of the at least one end of the wire conductor is coiled about the first end section of the terminal member. 
     
     
       7. A magnetic switch comprising:
 a housing; 
 a coil assembly arranged within the housing, the coil assembly including a wire conductor having at least one end; 
 a terminal mounted externally to the housing; and 
 a terminal member mounted within the housing between the coil assembly and the terminal, the terminal member including a first end section, a second end section and an opening positioned between the first and second end sections, the at least one end of the wire conductor extending into the opening and being joined to the terminal member through a mechanical bond and an electrical connection, the second end section being configured and disposed to establish a mechanical link and an electrical connection with the terminal. 
 
     
     
       8. The magnetic switch according to  claim 7 , wherein the terminal includes a connecting surface having an opening, the second end section of the terminal member being configured and disposed to extend through the opening and engage the connecting surface to establish the mechanical link. 
     
     
       9. The magnetic switch according to  claim 8 , wherein the second end section of the terminal member includes a first connecting member and a second connecting member, each of the first and second connecting members being configured and disposed to be independently deformed to engage the connecting surface to establish the mechanical link. 
     
     
       10. The magnetic switch according to  claim 8 , further comprising: an amount of solder arranged at the second end section of the terminal member, the amount of being configured and disposed to facilitate the electrical connection with the terminal. 
     
     
       11. The magnetic switch according to  claim 7 , further comprising: a diode having a first diode terminal and a second diode terminal, the opening includes a first opening portion having a size that is greater than a size of an outer perimeter of at least one of the first and second diode terminals and a second opening portion having a size that is less than the size of the outer perimeter of the one of the first and second diode terminals. 
     
     
       12. The magnetic switch according to  claim 7 , wherein a portion of the at least one end of the wire conductor is coiled about the first end section of the terminal member. 
     
     
       13. A method of connecting an end portion of a wire conductor and a diode terminal to a terminal of an electric machine, the method comprising:
 inserting a first end of the wire conductor through an opening formed in the terminal member; 
 mechanically retaining the first end of the wire conductor to a first end section of a the terminal member at the opening; 
 establishing an electrical connection between the first end of the wire conductor and the first end section of the terminal member at the opening; 
 inserting a second end section of the terminal member into an opening formed in a terminal; 
 mechanically linking the second end section of the terminal member to the terminal; and 
 establishing an electrical connection between the second end section of the terminal member and the terminal. 
 
     
     
       14. The method of  claim 13 , wherein mechanically retaining the first end of the wire conductor to the terminal member further includes coiling the first end of the wire conductor about the first end section of the terminal member. 
     
     
       15. The method of  claim 14 , wherein mechanically retaining the first end of the wire conductor to the terminal member further capturing a diode terminal in the opening, the opening having a size that is smaller than a size of an outer perimeter of the diode terminal. 
     
     
       16. The method of  claim 15 , wherein establishing the electrical connection between the first end of the wire conductor and the first end section of the terminal member further includes soldering the first end of the wire conductor and the diode terminal to the first end section of the terminal member. 
     
     
       17. The method of  claim 13 , wherein mechanically linking the second end section of the terminal member to the terminal includes:
 passing the second end section of the terminal member through an opening formed in the terminal; and 
 deforming a connecting member provided at the second end section of the terminal member to engage with the terminal. 
 
     
     
       18. The method of  claim 17 , wherein establishing the electrical connection between the second end section of the terminal member and the terminal includes soldering the connecting member to the terminal.